SOLUTION BROCHURE
ECU Test System
End-of-Line Functional Test of Automotive Electronic Control Units
“Partnering with NI to solve our ECU functional test challenges has lowered our total
cost of test while maintaining high quality standards. By standardizing on NI testers
we reduced cycle and development time, increased system re-use, and made
debugging, deploying, and maintenance easier.”
– Sergio Mejia, I&IE Test Engineer at Vitesco Technologies
CONTENTS
The Challenge ............................................................................................................................................... 3
The Solution .................................................................................................................................................. 4
ECU Functional Test Workflow ................................................................................................................. 5
Supporting Your Business Initiatives through Test ................................................................................... 6
ECU Test System Software .......................................................................................................................... 7
Test Executive ........................................................................................................................................... 8
Signal Routing ........................................................................................................................................... 8
Instrument Configuration and Debugging .................................................................................................. 8
ECU Test System Hardware ......................................................................................................................... 9
Hardware Specifications ............................................................................................................................ 9
PXI Instrumentation Options ................................................................................................................... 10
Switch Load and Signal Conditioning ...................................................................................................... 11
Mass Interconnect ................................................................................................................................... 11
DC Power Supplies ................................................................................................................................. 12
Electronic Loads ...................................................................................................................................... 12
Topology Options .................................................................................................................................... 13
Simplified Hardware Maintenance ........................................................................................................... 13
Services and Support .................................................................................................................................. 15
ECU Test System Service Offerings ....................................................................................................... 15
Additional Services Available .................................................................................................................. 16
Large-Scale Global Deployments ............................................................................................................ 17
Next Steps ................................................................................................................................................... 18
Page 2 | ni.com/automotive | ECU Test System
The Challenge
The number of electronic control units (ECUs) in modern consumer vehicles has grown sharply as a
result of the paradigm shift from mechanical to electronic systems. In many ways, ECUs power all the
innovations we see in vehicle comfort, safety, connectivity, and efficiency. ECUs increase convenience,
such as the nuanced adjustment a luxury seat makes as soon as a driver’s key fob enters the vehicle, or
when rain sensing windshield wipers automatically speed up during a downpour. ECUs drive efficiency
through precise engine control, harnessing more performance from the same internal combustion engine.
And they increase safety through automatic emergency breaking and lane departure warning systems.
Together, a network of over 100 ECUs comprise the “brain” of a modern vehicle.
We know these innovations complicate production test of ECUs. Outbidding the competition puts more
pressure on production test managers to meet the delivery deadline. Because ECUs are often safety
critical, especially in engine control and passive safety, thorough testing is essential and must somehow
be achieved despite time constraints and cost control measures. Failure to do so risks peoples’ lives and
threatens consumer trust.
NI’s ECU Test System (ECUTS) helps production test managers deploy functional testers more efficiently
and with greater agility, revolutionizing end-of-line (EOL) testing with a standardized, high performance
architecture. Greater agility is increasingly necessary to meet test requirements on time and within
budget. To help you achieve your objectives faster, we’re innovating where others aren’t. We don’t
believe that test innovation should be limited to ADAS, EV, and V2X, especially when there is so much
room for improvement in the performance, intelligence, and procurement of body, chassis, and
transmission ECU functional testers. Lowering the cost of test for these components frees up both
monetary and cognitive capital so test engineers can innovate in new areas while maintaining consumer
confidence necessary for these systems.
With NI’s ECUTS, you can position test as a competitive advantage, not just a cost center. Imagine what
your test department could achieve if it wasn’t always scrambling to meet the next deadline.
Page 3 | ni.com/automotive | ECU Test System
The Solution
The ECU Test System (ECUTS) is a functional tester for endof-line (EOL) test of automotive ECUs built on NI’s adaptive,
open technology. Our systems R&D engineers have integrated
the following core components into this system, so you can
focus your energy on creating a first-rate test program.
✓
Core Rack: Safety, Display, Power
✓
Instrumentation
✓
Custom Cabling
✓
Mass Interconnect
✓
Loads and High-Power Switching
✓
Low-Power Switching
Standardizing on this tester can reduce capital and operational
expenses through efficiency driven by asset and architecture
reuse, streamlined global supply, and service programs.
The ECUTS also reduces test time and floor space through
parallel test powered by a best-in-class test executive and a
portfolio of high quality I/O.
Figure 1. NI ECU Test System
Figure 2. NI ECU Test System Architecture
Page 4 | ni.com/automotive | ECU Test System
ECU Functional Test Workflow
Page 5 | ni.com/automotive | ECU Test System
Supporting Your Business Initiatives through Test
At NI, we go beyond a traditional vendor/client relationship and support you with solutions and services
that are right for your specific business needs. We can partner with you to drive efficiency and
differentiate through new technology or processes. Below are several areas in which we have seen
production test directors realize value through partnering with NI.
•
Standardization: NI’s modular hardware and open software is ideal for standard platform
development, as you can easily reuse and expand components with minimal redesign for a wide
range of functionality.
•
Internal Proficiency: On-site bring-up services ensure you are up and running swiftly and
smoothly. Customer education courses are available to help operators and developers do their
jobs more effectively. A single NI software toolchain that applies to multiple engineering
disciplines, combined with a thriving global developer community, encourages test proficiency at
the individual and team level.
•
Outsourcing ROI: By combining consultation, support, and full integration services, you can
balance in-house and outsourced work without putting deadlines or build quality at risk.
•
Operational Expense: Industry-renowned reliability, production-optimized test and data
management software, and comprehensive services and support ensure minimized downtime,
real-time operational insight, and cost-effective sustaining strategies.
•
Capital Expense: Scalable, future-proof architectures, multi-up test capability, and high-channel
count instrumentation maximize return on capital investments and protect against large
unexpected costs.
“Using the NI automated test platform, we achieved shorter development time and
faster test speed required for functional tests of powertrain ECUs in manufacturing.
We reduced development time to 1/6 of the previous system and lowered system
cost to 70 percent with 15 percent faster test time.”
–Minsuk Ko, Manager, Ph. D., Hyundai Kefico
Page 6 | ni.com/automotive | ECU Test System
ECU Test System Software
The ECU Test System (ECUTS) comes with
the software you need to design, deploy,
and manage test systems. It includes the
following software by default and runs on
the Windows 10 based PXI controller.
TestStand serves as the test executive to
manage and execute test sequences
(plans). InstrumentStudio™ application
software provides a higher abstraction to
configure and debug test steps, and Switch
Executive helps manage signal routing.
Figure 3. ECUTS Software Workflow
NI Product
Description
TestStand
Industry-standard test management software for custom development and
automated execution of test sequences.
TestStand ECU Toolkit
(Early Access H2 2020)
ECUTS specific software that integrates the workflow between TestStand
and InstrumentStudio.
Switch Executive
Switch management and routing application that accelerates development
and simplifies maintenance of switch systems.
InstrumentStudio
Software that provides interactive bring-up and debugging of instruments.
ECU Test System
Maintenance Software
ECUTS specific software that lets you interactively visualize, diagnose, and
test ECU Test System hardware components and perform continuity testing
using the Field Diagnostic Tester.
LabVIEW Base
Graphical programming environment that simplifies the design of distributed
test, measurement, and control systems.
SystemLink™ Client
Client license for each test system connecting to the SystemLink Server.
Figure 4. ECUTS Software Components Split by the Functions They Perform
Page 7 | ni.com/automotive | ECU Test System
Test Executive
TestStand
This industry-standard test management software functions as the test executive and is ready to run.
•
Create, execute, and debug test sequences
•
Reuse code developed in any programming language
•
Generate reports and integrate with databases
•
Develop or connect to professional operator interfaces
•
Increase throughput with parallel testing and auto scheduling
•
Meet custom requirements with an open and extensible framework
TestStand ECU Toolkit
This toolkit integrates the workflow between TestStand and InstrumentStudio to easily configure
instruments within the ECUTS.
•
Controls instruments in TestStand based on configurations defined in InstrumentStudio
•
Debugs instruments using InstrumentStudio while running a test sequence in TestStand
•
Works for measurement instruments supported only in the ECUTS
Signal Routing
Switch Executive
This intelligent switch management and routing application accelerates development and simplifies
maintenance of switch systems.
•
Graphical and automatic routing options
•
Intuitive channel aliases (“DMM_HI” versus “r129”)
•
Custom naming for individual routes and route groups
•
Tight integration with TestStand
•
API for LabVIEW and LabWindows™/CVI
NI Switch Health Center
To simplify relay maintenance and reliability in high-channel-count systems, all NI SwitchBlock modules
and PXI Matrix modules are shipped with the NI Switch Health Center, which includes an integrated relay
test and provides access to the relay-count tracking data stored on the NI switch hardware.
Instrument Configuration and Debugging
InstrumentStudio
This application software helps you unify your display, export instrument configurations for a higher-level
starting point, and monitor and debug your automated test system.
•
Configure hardware using familiar instrument front panels
•
Easily navigate web browser-like user interface
•
Export data and screenshots
•
Export instrument configurations to automation code
•
Enjoy a simplified debug experience for automated test
Page 8 | ni.com/automotive | ECU Test System
ECU Test System Hardware
Monitor
Core Rack
PXI Instrumentation
Mass Interconnect
SLSC Load Switching
and Management
Optional Tray
Power Supplies
External Loads or
eLoads
Figure 5. Side View of Internal Components of the ECU Test System (ECUTS)
Hardware Specifications
Core Rack
Power Supply
ESD (IEC 61340-5-1), RAL 7035 gray paint
24 U (1358.9 mm height)
Power Input: 200–240 V (1-Phase, 3.8 kW)
PDU DC Output: + 12 V, + 24 V
200 W (20/36/60 V) and 400 W (20/36/60 V).
PXI Instrumentation
High performance PXIe-1084 chassis
High throughput PXIe-8861 quad-core controller
Configure up to 16 additional PXI instruments and I/O modules
Automotive
Communications
CAN, LIN, RS232, GPIB
PXI Pin Switch
2-wire, support up to four each 4x64, 8x32, or 16x16 matrix modules, to
create matrices of 4x256, 8x128, or 16x64 respectively
EMR, 60 V/2 A (60 W)
8 A, up to 96-ch with current measurement
30 A, up to 24-ch with current measurement
Load Switching and
Management
Loads
Space for either external load or electronic load (eLoad) 100 W (60 V/20 A)
8-ch or 350 W (60 V/20 A) 4-ch
Mass Interconnect
Virginia Panel Corporation (VPC) 9025, 25 slots
Optional tray
Page 9 | ni.com/automotive | ECU Test System
PXI Instrumentation Options
Combined with a chassis and controller, PXI systems feature high-throughput data movement using PCI
Express bus interfaces and subnanosecond synchronization with integrated timing and triggering. Select
up to 16 PXI modules from the standard options listed below to create the ideal I/O set to meet your ECU
test requirements.
Instrument
Max. per
System
Description
Digital Multimeter (DMM)
4
PXIe-4081 DMM (DC current, DC voltage, resistance)
Source Measurement
Unit (SMU)
4
PXIe-4139 1-ch, 60 V, 3 A
Programmable Power
Supply (PSU)
4
PXIe-4112 2-ch, 60 V, 1 A
Scope
2
PXIe-5105 8-ch, 60 MHz,12-bit, ± 15 V
Analog Input (AI)
4
PXIe-4310 8-ch isolated, 400 kS/s/ch, ± 60 V
Function Generator
2
PXIe-5413 2-ch, 20 MHz,16-bit, 24 Vpp
Analog Output (AO)
8
PXIe-4322 8-ch isolated, 250 kS/s/ch, ± 16 V
Digital Input (DI)
1
PXI-6515 32-ch sink/source, ± 30 VDC, bank-isolated
Digital Output (DO)
1
PXI-6515 32-ch sink, ± 30 VDC, bank-isolated
Relay
1
PXI-2564 16-ch, 5 A and PXI-2520 80-ch, 2 A SPST relay
Page 10 | ni.com/automotive | ECU Test System
Switch Load and Signal Conditioning
NI Switch Load and Signal Conditioning (SLSC) hardware extends the PXI platform with front-end
modules for load switching and management. With standardized connectivity and form factor, it eliminates
the fault-prone process of point-to-point wiring, simplifying the overall system by handling small to
medium loads on a simple circuit card. The ECUTS leverages the SLSC hardware below, which enables
larger switches for fault insertion, adds custom signal conditioning, and reduces signal routing complexity.
Instrument
Chassis for SLSC
SLSC-12001
8 A Fault Insertion Unit (FIU)
SLSC- 12251
30 A Fault Insertion Unit (FIU)
SLSC-12252
Description
12-slot chassis provides power, active cooling, triggering, and a
communication interface to SLSC modules
Provides 16 channels for 8 A continuous RMS maximum current for
load switch routes with current measurement
Provides 8 channels for 30 A continuous RMS maximum current for
load switch routes with current measurement
The SLSC-12251/2 can present the DUT with the following errors: open circuit, pin shorted to two
different potentials (for example, Vbatt or GND), and short to another pin. These modules provide current
sensing on each channel when coupled with a measurement module in a data acquisition system. This
functionality can be used to measure current profiles, for example, measuring the profile of a solenoid
injector.
Mass Interconnect
NI partnered with the Virginia Panel Corporation (VPC) to provide a mass interconnect that enables rapid
system changeover through a standardized approach and minimizes downtime and reduces maintenance
with reliable long-term operation.
Figure 6. Mass Interconnect Pin Out
Page 11 | ni.com/automotive | ECU Test System
This mass interconnect receiver arrangement is standardized
across all ECU Test Systems, which allows for easy pin testing
with the Field Diagnostic Tester (FDT). The layout was designed
to avoid cable crossovers with symmetry, keep cables as straight
as possible, and leave blank spaces for future expansion or
customization.
Both the VPC 9025 position modular mass interconnect and VPC
9025TR (tray option) are available with the ECUTS.
Figure 7. VPC 9025 TR with Fixture and DUTs
DC Power Supplies
The ECUTS includes options to include 2U, 1/6 rack-width, single-channel, and rack mount DC
programmable power supplies. Based on your requirements, you can choose one of two options.
RMX-4101 comes in four versions and offers up to 216 W of power with options that support up to 100
VDC or 10 A.
RMX-4102 offers up to 432 W of power with options that support up to 100 VDC or 20 A.
Electronic Loads
Built for automated test and measurement, electronic load devices can sink power at various current and
voltage levels for power supply design, quality inspection, and functional tests. Their modular design and
multiple operating modes help them simulate the real load that a power source handles in its actual
application. They also feature buttons and knobs for interactive use, as well as USB or RS232 interface
options for automation. You can connect multiple loads in parallel to increase your system’s overall power
capacity.
Load Module Model
RMX-4003
RMX-4005
Channels
2
1
Max. Power
100 W/100 W
350 W
Max. Voltage
80 V/80 V
80 V
Max. Current
20 A/20 A
70 A
Instead of the RMX electronic loads, you can also choose to use an external load box with dimensions 5U
(200 mm) height, 530 mm depth, and 480 mm width.
Page 12 | ni.com/automotive | ECU Test System
Topology Options
There are several topology options you can select for testing DUTs in parallel based on your desired
throughput, DUT complexity, and budget requirements.
Figure 8. Selection of ECUTS Topology Options
A NEST refers to the place a DUT connects to a text fixture; each NEST has dedicated instrumentation
and test pins for parallel test execution. One NEST can hold several DUTs, and those DUTs will share
instrumentation. Parallel testing can result in a 10–40 percent reduction in test time compared to previous
testers.
Figure 9. Example Hardware Configurations for Different Topologies
Simplified Hardware Maintenance
Because system uptime and reliability are essential in a production test environment, the ECUTS includes
options to simplify servicing and maintenance: the ECU Test System Maintenance Software (included in
the ECUTS Software Suite) and the Field Diagnostics Tester (optional hardware add-on) for automated
pin continuity checking. With these tools, if just one pin breaks in this complex system, it can be identified
in minutes rather than hours.
Figure 10. Exterior and Interior View of a Field Diagnostics Tester
Page 13 | ni.com/automotive | ECU Test System
Field Diagnostic Tester
You have the option of including a Field Diagnostics Tester (FDT) with the ECUTS for higher
maintenance and serviceability of the system. This tool performs continuity testing to the mass
termination and is housed in the 15-inch deep ITA enclosure compatible with the VPC 9025 rack-mount
receiver. Diagnostics tests are performed using the ECU Test System Maintenance Software. Because
the mass interconnect layout is standard on all ECU Test Systems, one FDT can service multiple test
systems.
Note: The FDT works only for pre-defined slots and pins. It does not cover open slots (J3, J11, J13, J15,
J17, and J25).
When paired with an FDT, the ECU Test System Maintenance Software provides a report of components
expected in the system and performs a continuity check on all pre-defined slots and pins.
Figure 11. Example First Page of an ECUTS Maintenance Report
Page 14 | ni.com/automotive | ECU Test System
Services and Support
You expect NI systems to help you solve some of the most challenging engineering problems; expect the
same level of capability in our services. With every ECU Test System (ECUTS) deployment, we partner
with you to determine the level of service that best meets your application needs and ensures long-term
success.
Receive Basic Support: Obtain peace of mind through support from ECUTS experts to
accompany your in-house maintenance operations. One year of our Basic Service
Program is included with every ECUTS.
Maximize Production Uptime: Maximize uptime of your ECUTS with faster turnaround
times from NI when hardware fails or expert support is needed. NI has the global
infrastructure and resources to help you manage a tiered sparing model across your
ECUTS installed base. We provide flexible service options from a regional inventory of
spares that can be delivered in less than 24 hours to an on-site spares inventory.
Optimize Tester Performance: With over 10 years’ experience calibrating PXI
instruments and more than 20 years working with calibrating precision instrumentation,
we’re well equipped to provide on-site and laboratory calibration options that meet your
needs.
Maximize Efficiency: To help you quickly develop and deploy testers, NI offers a variety
of options for engineering services, such as test program development, custom operator
interface (OI) development, test cell integration, and tester migration. We also deliver a
spectrum of services to help integrate ECUTS into your factory and train your engineers,
technicians, and operators.
Achieve Longevity: NI knows every application has different requirements for support
and longevity, so we’re committed to providing the life-cycle support you need for your
applications. We offer consultative engagements on the life-cycle status of products,
recommended updates, and planning related to sustaining engineering.
ECU Test System Service Offerings
Software Support
Access updates and bug fixes
Repair and Replacement
Minimize downtime
Technical Support
Resolve issues quickly
Basic
Full
Access to SW
Updates
Access to SW
Updates
3–5 Days
Replacement
<24 Hour
Replacement
Technical Support
8x5
Technical Support
8x5
Field and Remote Services
Troubleshooting
and Support
Fixed maintenance cost
Life-Cycle Management
Mitigate obsolescence risk
Training
Increase productivity
Standard Product
Notifications
Standard Product
Notifications
Online Operator
and Maintenance
Training
Online Operator
and Maintenance
Training
Custom
Scope to be defined with
customer on a case-by-case
basis
Availability of service programs varies by region. Contact your account manager for more information.
Page 15 | ni.com/automotive | ECU Test System
Additional Services Available
Calibration
Quality measurements and
traceability
Bring-Up Assistance
Laboratory Calibration
On-site Calibration
Calibration Replacement
On-site or Remote Tester Bring-Up
Hassle-free commissioning
Training
Reduce development time
Professional
Services
Instructor-Led, On-Site and/or Customized Training
Operator and/or Maintenance Training
Test Engineer Training
Integration Engineering Services
Methodology Consulting Services
Resident Engineering Services
Calibration Levels Offered
Calibration Standards
NI Calibration
Level
Industry Requirements
Typical
Industries
No Industry Standard
(ISO 9001 umbrella
may be used)
Traceable
Verification and adjustment of measurement
performance using calibration procedures
and measurement standards traceable to SI
units (NIST traceable). Includes “As Found”
and “As Left” data.
All
ISO/IEC 17025
Accredited
Traceable calibration level plus detailed
measurement uncertainty for each test point.
Includes the official logo of the accreditation
body Performed at an ISO 17025-accredited
laboratory
Transportation
(Automotive
IATF 16949),
Medical
ANSI/NCSLI Z540.11994
Compliant
Traceable calibration level plus a
measurement uncertainty evaluation; identify
test points where ratio is less than specified
(NI uses 4:1 ratio).
Defense,
Aerospace
NI Traceable and Compliant calibrations are performed in an ISO 17025 Lab even though it’s not
required. NI Calibration Labs are accredited by A2LA. (NI China Calibration Lab accreditation in
progress.) NI-manufactured products that do not have accredited service availability can be covered
under IATF 16949 for a specific customer in some cases.
Methodology Consulting Services
With more than 40 years’ test experience, NI is an expert in test-related processes and strategies. We
provide a framework to help you evaluate your people, processes, and technology, and recommend a test
strategy appropriately customized to your business. Let’s work together to solidify a business case that
articulates your future state and expected program ROI to secure the funding you need.
Planning and project management consulting helps build a project-execution plan that keeps teams on
track to hit major development milestones. Together, we can help you establish priorities, identify the right
resources, and make trade-offs to optimize cost without putting projects at risk.
Integration Engineering Services
With global solution centers and engineers in more than 40 countries supported by more than 900
Alliance Partner companies, NI offers design and development assistance in every region and industry.
Our engineers help you mitigate risk, develop faster, and reduce costs through project management,
architecture development, and system documentation to deliver an integrated solution.
Education Services
Page 16 | ni.com/automotive | ECU Test System
NI Education Services helps ensure test customers realize the full potential of NI systems and end users
achieve personal success. Our training curriculum is available in a variety of formats—including virtual
classrooms and private on-site events—and is designed by role and by task so users can quickly obtain
the knowledge and skills they need.
System Completion
Interested in a turnkey solution? Contact your NI sales manager to learn about various options for second
level integration provided by our Integration Engineering Services or an Alliance Partner. Options include
test program development, custom operator interface development, test fixture development, production
line integration, tester migration, and more.
Figure 12. Services Offered by Alliance Partners Help Ensure Your Success
Large-Scale Global Deployments
Our footprint of service centers and manufacturing sites around the world ensure the success of your
large-scale global deployments.
Figure 13. NI’s Global Footprint of Service and Calibration Centers
Page 17 | ni.com/automotive | ECU Test System
Next Steps
Contact your NI account manager or call or email us to learn more about how the ECU Test System can
help you improve product quality and accelerate testing timelines.
1-888-280-7645
info@ni.com
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